Tub insert system for top loading washer

ABSTRACT

A washing machine tub insert system is provided that prevents the wash tub from impacting the washing machine cabinet during shipping and handling. The tub insert system may be made from a bottom panel and an insert that lock together. The insert outwardly biases locking members against the cabinet rim and against the tub to minimize relative movement of the tub and cabinet, thereby reducing or eliminating the possibility of the wash tub damaging the washing machine cabinet.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.14/285,859, filed May 23, 2014. U.S. application Ser. No. 14/285,859 isincorporated here by reference in its entirety to provide continuity ofdisclosure.

BACKGROUND

Field of the Invention

This patent relates to appliance packaging. More particularly, thispatent relates to a device that fits inside the top opening of a washingmachine to prevent the wash tub from moving relative to the outercabinet during shipping and handling.

Description of the Related Art

Top-loading washing machines generally comprise a wash tub disposedwithin a cabinet or housing. Some washing machines have a centralpivoting agitator extending upwardly from the bottom of the wash tub andoperably connected to a motor located below the tub. Other washingmachines lack this central agitator and instead have ridges located onthe inside of the wash tub to assist with the agitating function. Ineither type of machine the clearance between the wash tub and theappliance cabinet is often small, and so the cabinet is susceptible todamage from impacts from the wash tub when the appliance is moved duringshipping.

Thus there is a need for a device that locks the wash tub in place orotherwise prevents the tub from impacting the appliance cabinet when thewashing machine is moved.

SUMMARY OF THE INVENTION

The present invention is a washing machine tub insert system forplacement into a washing machine of the type having a wash tub disposedwithin a cabinet. The tub insert prevents the wash tub from impactingthe washing machine cabinet during shipping and handling.

In one aspect the invention is a blank for constructing a unitary tubinsert system for a washing machine of the type having a wash tublocated within a cabinet, the cabinet having a top surface having a rimdefining a top opening having a width W. The blank comprises a bottompanel, a top panel and an insert panel. The bottom panel defines a mainpanel opening. The top panel is foldably attached to the bottom panelalong a first fold line.

The insert panel comprises a first section and a second section. Thefirst section is foldably attached to the top panel along a second foldline. The second section is foldably attached to the first section alonga third fold line. The first and second sections are configured to fitwithin the main panel opening when the insert panel is folded along thethird fold line into an elongated, three-dimensional V-shaped structureand the top panel is folded over so that it is overlying the bottompanel.

The insert panel may further comprise a flap foldably attached to thesecond section along a fourth fold line. The flap is configured to layflat against the bottom panel when the insert panel is folded along thethird fold line into the three-dimensional V-shaped structure and thetop panel is folded along the first fold line so that it is overlyingthe bottom panel.

The bottom panel may comprise a main panel and inwardly opposing tabsconnected to the main panel along tab fold lines. The insert panel maybe configured to push against and bias the tabs outward, toward thecabinet rim, when the insert panel is folded along the third fold lineinto a V-shaped structure and the top panel is folded over on top of thebottom panel.

In another aspect, the disclosure relates to a tub insert system madefrom a folded blank. The system comprises a bottom panel, a top panel,an insert panel and optional foam locking members. The bottom panelcomprises a substantially planar main panel configured to overlay thewashing machine top opening and opposing tabs foldably attached to themain panel along tab fold lines. The main panel defines a main panelopening. The top panel may be connected to the bottom panel along afirst fold line. The top panel overlays the bottom panel.

The insert panel comprises a first section and a second section. Thefirst section is connected to the top panel along a second fold line.The second section is connected to the first section along a third foldline. The first and second sections form an elongated three-dimensionalstructure having opposing ends. The three-dimensional structure islocated on a side of the main panel opposite the top panel, and biasesthe tabs away from each other.

The optional locking members may be affixed to the outer surface of eachtab and may be configured to contact the wash tub and the cabinet.

In another aspect the disclosure relates to a combination washingmachine and tub insert system. The washing machine comprises a wash tublocated within a cabinet, the cabinet having a top surface having a rimdefining a top opening having a width W.

The tub insert system is made from a folded blank and comprises a bottompanel, a top panel, a three-dimensional structure and optional lockingmembers. The bottom panel comprises a substantially planar main panellocated adjacent the cabinet top surface and overlying the washingmachine top opening. The bottom panel further comprises opposing tabsfoldably attached to the main panel along flap fold lines. The mainpanel defines a main panel opening substantially overlying the washingmachine top opening. The top panel 28 may be substantially U-shaped andmay be connected to the bottom panel along a first fold line. The toppanel overlies the bottom panel.

The three-dimensional structure may be foldably attached to the toppanel and have a substantially V-shape profile and opposing ends. Thethree-dimensional structure extends into the washing machine and biasesthe tabs away from each other.

The three-dimensional structure may comprise a first section and asecond section. The first section may be connected to the top panelalong a second fold line. The second section may be connected to thefirst section along a third fold line. The first and second sectionsform an elongated three-dimensional structure having a substantiallyV-shape profile.

The three-dimensional structure may further comprise a flap connected tothe second section along a fourth fold line. The flap may be locatedadjacent the main panel on a side of the main panel away from thecabinet top surface to stabilize the three-dimensional structure.

The optional locking members may be affixed to an outer surface of eachtab and configured to contact the wash tub and the cabinet. Thethree-dimensional structure has a maximum end-to-end length equal to orless than the width W of the washing machine top opening.

THE DRAWINGS

FIG. 1 is a partial cutaway view of a washing machine.

FIG. 2 is a top plan view of a blank for making a tub insert systemaccording to the present invention.

FIG. 3 is a perspective view of a first embodiment of a tub insertsystem shown partially folded.

FIG. 4 is a perspective view of the tub insert of FIG. 3 showncompletely folded and installed inside a washing machine tub. Thewashing machine lid is removed for clarity.

FIG. 5 is a side cutaway view of a tub insert system installed inside awashing machine tub.

FIG. 6 is a side cutaway view of a second embodiment of a tub insertsystem installed inside a washing machine tub.

FIG. 7 is an exploded perspective view of an alternative embodiment of atub insert system according to the disclosure.

DETAILED DESCRIPTION OF THE INVENTION

While this invention may be embodied in many forms, there is shown inthe drawings and will herein be described in detail one or moreembodiments with the understanding that this disclosure is to beconsidered an exemplification of the principles of the invention and isnot intended to limit the invention to the illustrated embodiments.

Turning to the drawings, there is shown in FIG. 1 a partial cutaway viewof a washing machine 12 in which the wash tub 14 is located within ametal cabinet 16. The cabinet 16 has an inwardly extending rim 20 thatdefines a top opening 17 in the washing machine top surface 18. The topopening 17 may have a width W which, if the top opening 17 is circular,is also the diameter of the top opening 17. A hinged lid 21 may coverthe top opening 17. A control panel 19, shown only in FIG. 3, may extendupward from the rear of the cabinet 16.

During shipping and handling, the wash tub 14 can swing from its centerposition and impact the walls of the cabinet 16 from the inside if notrestrained. These impacts can produce a cosmetic defect to the outsideof the cabinet 16. This problem is solved by placing inside the washingmachine 12 a tub insert system 10 made according to the presentdisclosure.

The Tub Insert System

The tub insert system 10 may be formed using a single, unitary blank 22,preferably made of corrugated board. FIG. 2 is a top plan view of ablank 22 for making a tub insert system 10 according to the presentdisclosure. The blank 22 comprises a substantially rectangular bottompanel 24, a substantially U-shaped top panel 28 and an insert panel 32.The blank 22 preferably is made of corrugated board.

The bottom panel 24 comprises a substantially rectangular main panel 46and opposing tabs 48 connected to the main panel 46 along tab fold lines50. The main panel 46 defines a main panel opening 26 which may berectangular as shown in the figure. The four sides of the rectangularmain panel opening 26 may be formed by two opposing, parallel side edges23 and the two opposing, parallel tab fold lines 50. The main panelopening 26 is configured (sized and positioned) to overlay the washingmachine top opening 17 when the tub insert system 10 is installed,allowing the tabs 48 to be folded downward, into the top opening 17.

The top panel 28 is foldably attached to the bottom panel 24 along afirst fold line 30. In an alternative embodiment the top panel 28 (andthe insert panel 32) together make up a separate piece.

The insert panel 32 comprises a substantially planar first section 34, asubstantially planar second section 36, and a flap 42. The first section34 is connected to the top panel 28 along a second fold line 38substantially parallel to the first fold line 30. The second section 36is connected to the first section 34 along a third fold line 40. Theflap 42 is connected to the second section 36 along a fourth fold line44.

As discussed in more detail below with respect to FIGS. 3-5, togetherthe first and second sections 34, 36 form an elongated three-dimensionalstructure having a substantially V-shape profile, opposing ends 45, anda maximum end-to-end length equal to or less than the width W of thewashing machine top opening 17. The third fold line 40 forms a bottomedge of the three-dimensional structure and the second fold line 38 andthe fourth fold line 44 form the top edges of the three-dimensionalstructure. The insert panel 32 is configured so that thethree-dimensional structure formed by the first and second sections 34,36 fits through the main panel opening 26 and into washing machine topopening 17.

Assembly

FIG. 3 is a perspective view of a first embodiment of a tub insertsystem 10 according to the present invention, shown in a partiallyfolded state prior to being installed inside a washing machine 12. Inthis first embodiment the tub insert system 10 comprises the blank 22and two locking members 60 affixed to the blank 22. The locking members60 preferably are made of expanded foam material.

To make the tub insert system 10, the blank 22 of FIG. 2 may be foldedalong fold lines 40 and 44 to form the V-shaped structure. The tabs 48may be folded downward along fold lines 50 so that their outwardlyfacing surfaces 49 are facing away from each other as best shown in FIG.5. The blank 22 may then be folded along fold line 30 until the toppanel 28 overlies the bottom panel 24 and the V-shaped structure isinserted through the main panel opening 26 until it contacts the tabs 48and biases the tabs 48 outward, away from each other. If locking members60 are used, they may be adhered or otherwise affixed to the outerfacing surfaces 49 of the tabs 48. The tub insert system 10 is now readyto be placed over a washing machine opening 17 so that the lockingmembers 60 push against the cabinet rim 20 and against the tub 14 tominimize relative movement of the tub 14 and cabinet 16.

Installation and Use

FIG. 4 is a perspective view of a first embodiment of a tub insertsystem 10 installed inside a washing machine 12. The main panel 46 restsagainst the cabinet top surface 18 and covers all or a portion of thewashing machine top opening 17. The top panel 28 is completely foldedover on top of the bottom panel 24 and may lay flat against (abut) thebottom panel 24. The insert panel 32 has been folded into athree-dimensional V-shaped structure with its first and second sections34, 36 suspended below the main panel opening 26 and with the flap 42lying flat against the bottom panel 24. Preferably the insert panel 32is configured so that its side edges are substantially coextensive withthe side edges 23 of the main panel opening 26 when installed.

FIG. 5 is a side cutaway view of the tub insert system 10 installedinside a washing machine 12. When the tub insert system 10 is installed,the insert panel 32 biases the tabs 48 outwardly. More specifically, theV-shaped structure formed by the first and second sections 34, 36 of theinsert panel 32 outwardly biases the tabs 48, and thus the lockingmembers 60, against the cabinet rim 20 and against the tub 14 tominimize relative movement of the tub 14 and cabinet 16, therebyreducing or eliminating the possibility of the wash tub 14 swingingagainst or otherwise hitting the interior wall of the washing machinecabinet 16.

In this first embodiment the locking members 60 are adhered to the outerfacing surfaces 49 of the tabs 48 and contact the wash tub 14 and thecabinet rim 20 to minimize relative movement of the tub 14 and cabinet16.

In an alternative embodiment shown in FIG. 6, the tub insert systemconsists solely of a folded blank and does not include foam lockingmembers 60. Instead, the V-shaped structure formed by the first andsecond sections of the insert panel outwardly biases the tabs 48directly against the cabinet rim 20 and against the tub 14 to minimizerelative movement of the tub 14 and cabinet 16.

In still another embodiment the tub insert system comprises multiplefolded blanks, with or without foam locking members 60. For example, asshown in FIG. 7, the tub insert system 70 may comprise a flat bottompanel 72 and an insert 74 that lock together. The bottom panel 72comprises a substantially rectangular main panel 76 and opposing tabs 78connected to the main panel 76 along tab fold lines 80. The main panel76 defines a main panel opening 82 which may be rectangular as shown inthe figure. The four sides of the rectangular main panel opening 82 maybe formed by two opposing, parallel side edges 83 and the two opposing,parallel tab fold lines 80. The main panel opening 82 is configured(sized and positioned) to overlay the washing machine top opening 17when the tub insert system 70 is installed, allowing the tabs 78 to befolded downward, into the top opening 17.

The folded insert 74 may comprise two side panels 84 and two end panels86 joined together along corners 88. The end panels 86 may extenddownward from a top edge 89 and may be slanted inwardly (toward eachother). The end panels 86 contact and outwardly bias the tabs 78. If nolocking members are used, the end panels 86 bias the tabs 78 directlyagainst the cabinet rim 20 and against the tub 14 to minimize relativemovement of the tub 14 and cabinet 16. In the embodiment shown in FIG. 7expanded foam locking members 90 are affixed to the outer facing surfaceof the tabs 78. The insert 74 and, more specifically, the end panels 86,bias the locking members 90 against the cabinet rim 20 and against thetub 14 to minimize relative movement of the tub 14 and cabinet 16. Theinsert 74 may be made from folded material such as corrugated or may bea formed or molded three-dimensional structure. The two-dimensionalshape defined by the top edge 89 should be larger than the main panelopening 82 to hold the insert 74 in place within the main panel opening82 and to prevent the insert 74 from falling through the opening 82.

Applications

Thus there has been described a tub insert system for a top loadingwashing machine that protects the washing machine cabinet from beingdented from the inside by the washing machine tub. Preferably the tubinsert system is made from a folded corrugated blank and foam lockingmembers. The tub insert system can also be used with dryers having adryer tub mounted within a cabinet in a fashion similar to that of thewashing machine described herein.

It is understood that the embodiments of the invention described aboveare only particular examples which serve to illustrate the principles ofthe invention. Modifications and alternative embodiments of theinvention are contemplated which do not depart from the scope of theinvention as defined by the foregoing teachings and appended claims. Itis intended that the claims cover all such modifications and alternativeembodiments that fall within their scope.

The invention claimed is:
 1. A tub insert system comprising: a bottompanel comprising a substantially planar main panel and opposing tabsfoldably attached to the main panel along tab fold lines, the main paneldefining a main panel opening; and a separately formed insert disposedwithin the main panel opening and comprising two side panels and two endpanels joined together along corners, the insert having a top edge, theend panels extending downward from the top edge and slanted inwardlytoward each other, the end panels contacting the tabs and biasing thetabs away from each other.
 2. The tub insert system of claim 1 whereineach tab has an outer facing surface, the tub insert system furthercomprising: a locking member affixed to the outer facing surface of eachtab.
 3. A tub insert system comprising: a bottom panel comprising asubstantially planar main panel and opposing tabs foldably attached tothe main panel along tab fold lines, the main panel defining a mainpanel opening, each tab having an outer facing surface; a locking memberaffixed to the outer facing surface of each tab; and an insert disposedwithin the main panel opening and comprising two side panels and two endpanels joined together along corners, the end panels contacting the tabsand biasing the tabs away from each other, wherein the locking membersare made from expanded foam material.
 4. The tub insert system of claim3 wherein the bottom panel is made of corrugated board.
 5. The tubinsert system of claim 4 wherein the insert is made of corrugated board.6. The tub insert system of claim 4 wherein the insert is a moldedthree-dimensional structure.
 7. The tub insert of claim 1 wherein thebottom panel is made from a first blank and the insert is made from asecond blank.
 8. The tub insert of claim 1 wherein the main panelopening is rectangular.
 9. The tub insert of claim 8 wherein the inserttop edge is larger than the main panel opening.
 10. A combinationwashing machine and tub insert system, the washing machine comprising awash tub located within a cabinet, the cabinet having a top surfacehaving a rim defining a top opening, the top opening having a width, thetub insert system comprising: a bottom panel comprising a substantiallyplanar main panel and opposing tabs, the main panel located adjacent thecabinet top surface and overlying the washing machine top opening, theopposing tabs foldably attached to the main panel along tab fold lines,the main panel defining a main panel opening; and a separately formedinsert disposed within the main panel opening and extending into thewashing machine, the insert comprising two side panels and two endpanels joined together along corners, the end panels contacting the tabsand biasing the tabs away from each other.
 11. The combination washingmachine and tub insert system of claim 10 wherein each tab has an outerfacing surface, the combination washing machine and tub insert systemfurther comprising: a locking member affixed to the outer facing surfaceof each tab.
 12. The combination washing machine and tub insert systemof claim 11 wherein the locking members are made from expanded foammaterial.
 13. The combination washing machine and tub insert system ofclaim 12 wherein the bottom panel is made of corrugated board.
 14. Thecombination washing machine and tub insert system of claim 13 whereinthe insert is made of corrugated board.
 15. The combination washingmachine and tub insert system of claim 13 wherein the insert is a moldedthree-dimensional structure.
 16. The combination washing machine and tubinsert system of claim 10 wherein the bottom panel is made from a firstblank and the insert is made from a second blank.
 17. The combinationwashing machine and tub insert system of claim 10 wherein the insertcomprises a top edge that is larger than the main panel opening.
 18. Thecombination washing machine and tub insert system of claim 11 whereineach locking member is configured to impinge against the wash tub andthe cabinet.